Modular Crate

ABSTRACT

A shipping crate for long and heavy items which need to be shipped using the current dimension limitations of Common Carrier LTL (Less Than Truckload) specifications which is rectangular or six sided, diagonally braced so as to increase the length of the freight that can be carried, with one supporting joist from corner to diagonal corner to which freight within the modular crate of the present invention can be supported or bound.

FIELD OF THE INVENTION

The present invention relates to a shipping crate and, more particularly, to a shipping crate for long and heavy items which need to be shipped using the current dimension limitations of Common Carrier LTL (Less Than Truckload) specifications.

BACKGROUND OF THE INVENTION

The problem of shipping oversize Long and Heavy Breakable Panels (LHBP) such as sheets of glass, slabs of stone, engineered stone and some plastic composites is one that hasn't been easily addressed by usual commercial ground shipping systems, also known as, “Common Carriers”. Since most of the transport of freight is done with Common Carriers it is also the least expensive method to move freight. Using route logistics and transport hubs, Common Carrier Truck Companies are able to maximize the amount of freight in each truck and thus save energy and money. The problem with LHBP items longer than 90 inches is that their dimension, when they are crated, is longer than the width of a common trailer door (which is 92 inches in the United States) and so the crate cannot be lifted and moved inside the trailer with a forklift. A forklift can push the crate in sideways, but since the crate is too long to lift with regular sized forks, pressure must be exerted on the side of the crate and its breakable contents. Crates carrying glass or stone can weigh in excess of 4000 pounds because of the density of the material.

Pushing or dragging this weight with a forklift often damages the crate and leads to damaging of the contents. Moreover, Common Carriers will discontinue service if too many damage claims are filed. They may also increase freight fees for unusual handling of cargo. Finally even if LHBP items are handled this way, they can only be delivered to businesses with loading docks. Residential or business delivery using a powered lift gate would be impossible.

Large panes of glass, large slabs of stone and large slabs of engineered stone are usually only distributed locally to end users by local distribution centers using specially equipped “A”-Framed trucks. The materials supplied to the distribution centers or local distributors or wholesalers are by either Sea Containers for direct imports or large Flatbed Trucks from larger distribution centers or consolidators. The end user must have a forklift with crane/clamp attachment on site to receive the slabs or panes. Some glass distributors have cranes on their trucks to deliver glass to businesses that don't have heavy equipment. There are no present solutions for homeowners to receive long and heavy items, except that they could pick them up from the closest truck terminal which may be hundreds of miles away.

The other solutions of delivering slabs do not offer an efficient distribution method whereby uncommon material of just a few slabs or panes can be feasibly shipped nationwide or within a large region. The current methods also don't contemplate the delivery to homeowners. In both cases the logistical solutions existing today would be unfeasible and increase the use of energy.

It is therefore an object of the invention to make LHBP easily shippable by normal LTL common carrier trucks.

It is another object of the invention to make LHBP easily shippable by normal LTL common carrier trucks and allow crates to be delivered to residential addresses using powered lift gate.

It is another object of the invention to make LHBP easily shippable by normal LTL common carrier trucks and allow crates to be delivered to business addresses using powered lift gate.

It is another object of the invention to save energy by making LHBP easily shippable by normal LTL common carrier trucks which transport freight very efficiently.

It is another object of the invention to protect LHBP from breakage within the crate and through the process of handling and moving the crate.

It is another object of the invention to brace LHBP in the crate so that it is safe to move LHBP out of the crate.

It is another object of the invention to brace LHBP in the crate so that any force applied to the top of the crate is transmitted around the LHBP and to the ground.

It is another object of the invention to create a crate that is shaped so that it can be rotated slightly to move it into a narrow truck.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a rectangular or six sided crate where LHBP can be braced diagonally so as to increase the length of the freight that can be carried through narrower doorways. There is one supporting joist from corner to diagonal corner to which the LHBP can be supported or bound. There is a pyramidal brace structure, crossing this joist, from the bottom corner of one side of the crate to bottom corner of the opposite side of the crate, with the top of the pyramid being around the middle of the top of the LHBP freight. The six sided design has a double pyramidal brace structure. There are three designs which incorporate this diagonal and pyramidal idea for three different situations.

The first type is a rectangular design (FIG. 2) allows the long side of the crate to be easily moved into the back door of a common carrier trailer (with length of X). The long side of this crate would not fit into a narrower Bobtail truck door (with length of Y). This crate would easily allow LHBP of about 100″ if X is 91″. Although this is a modular size that is trucked easily, there are some situations where this crate may not be able to be delivered by powered liftgate. This would occur if the last leg of the journey from the freight terminal to the home or business was with a narrower Bobtail lift gate truck rather than a normal size lift gate trailer.

The second type is of six sided design (FIG. 3) so that it can be rotated slightly to fit it through an even smaller Bobtail truck door. This crate would easily allow LHBP of about 100″ if X is 91″. But this crate could also fit through the narrower door of a Bobtail truck so that it could be maneuvered on to a powered liftgate. If X is 91″ then Y is about 75″, which would accommodate just about any commercial truck door available. This is the best crate for home or business address delivery with a powered lift gate.

The third type (FIG. 4) is the same shape as the second type except larger. This type of crate can only be inserted or removed from a common carrier truck by rotating it slightly. This allows even larger items to be moved using a common carrier truck. If X=91″ on this crate then the LHBP can easily be 116″ long. This crate is best for business address delivery where a dock or forklift is available.

It is understood, of course, that while the forms of the invention herein shown and described include the best mode contemplated for carrying out the present invention, they are not intended to illustrate all possible forms thereof. It will also be understood that the words used are descriptive rather than limiting, and that various changes may be made without departing from the spirit or scope of the invention as claimed below.

BRIEF DESCRIPTION OF THE DRAWINGS

A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent, detailed description, in which:

FIG. 1. Element no. 1 is the LHBP in the crate. It is supported and aligned by element no. 2, a joist that goes from corner to opposite corner and attached to the sides of the crate. Elements nos. 3 form the pyramidal structure that supports the LHBP and also transfers weight from on top of the crate around the LHBP and to the floor, thus supporting and protecting the LHBP from heavy freight put on top of the crate. Element no. 4 are the diagonal corners on the crate so that it can be rotated slightly to move it though a narrow doorway. Element nos. 5 are the skids that the crate is on so that it can be manipulated by a fork lift truck or pallet jack.

The illustrations and examples provided herein are for explanatory purposes and are not intended to limit the scope of the appended claims, as those skilled in the art will make modifications to the invention for particular uses.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 is a perspective view of a crate in the preferred embodiment. Although the dimensions of the crate can be changed for various purposes, the six sided structure is the most flexible for final delivery purposes. The four sided crate in FIG. 2 is the least expensive to construct with the least amount of materials so it is the preferred embodiment for shipping where no lift gate delivery is required.

While I have shown and described only a few embodiments in accordance with the present invention, it is understood that the same is not limited thereto but is susceptible of numerous changes and modifications as known to those skilled in the art, and I therefore do not wish to be limited to the details shown and described herein, but intend to cover all such changes and modifications as are encompassed by the scope of the appended claims.

Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.

Having thus described the invention, what is desired to be protected by Bendah's Patent is presented in the subsequently appended claims.

The illustrations and examples provided herein are for explanatory purposes and are not intended to limit the scope of the appended claims, as those skilled in the art will make modifications to the invention for particular uses. 

1. A rectangular or six sided crate, diagonally braced so as to increase the length of the freight that can be carried, with one supporting joist from corner to diagonal corner to which freight within the modular crate of the present invention can be supported or bound.
 2. The device of claim 1 wherein the modular crate has a pyramidal brace structure, crossing this joist, from the bottom corner of one side of the crate to bottom corner of the opposite side of the crate, with the top of the pyramid being around the middle of the top of the freight.
 3. The device of claim 1 wherein the modular crate is of six sided design (FIG. 3) so that it can be rotated slightly to fit it though an even smaller Bobtail truck door.
 4. The device of claim 1 wherein the modular crate of the current invention embodies six vertical walls, a horizontal floor and lid and bi-directional freight holding devices.
 5. The device of claim 1 wherein the modular crate of the current invention embodies vertical leg supports used for weight distribution and vertical lift for mobility.
 6. The device of claim 1 wherein the modular crate of the current invention embodies cross member bracing for adjustable freight support while being placed in a diagonal manner.
 7. The device in claim 1 wherein the top of the pyramidal structure is fastened to the lid of the crate for increased stability of the freight.
 8. The device in claim 1 wherein various blocks and braces are attached to the floor of the crate to secure various sized material being shipped together.
 9. The device in claim 1 wherein other pyramidal structure are alongside the diagonal freight so that blocks and braces can be attached to them.
 10. The device in claim 1 wherein the top of the pyramidal structures in claim 9 is fastened to the pyramidal structure of claim
 2. 